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G G ene
eneral As
Hydrauli
Hydr
aulic Mini
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PC4000Asrev05
PC4000Asrev05
Edition 08/2005
Edition 08/2005
ral Assembly
sembly P P ro rocedure
c Mining Sho
ng Shovel PC
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____________________________
cedure
vel PC40
4000
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Summary of Contents for Komatsu PC4000
- Page 1 G G ene eneral As ral Assembly sembly P P ro rocedure cedure Hydr Hydrauli aulic Mini c Mining Sho ng Shovel PC vel PC40 4000 ____________ ____________________________ _____________________________ ____________________________ ______________________________ ________________ _ ____________ ____________________________ _____________________________ ____________________________ ______________________________ ________________ _ PC4000Asrev05 PC4000Asrev05 Edition 08/2005...
- Page 2 Ass Ass emb emb ly ly Pro Pro ced cedur ur e PC4000 e PC4000 Z23038 Z23038 Al Al l s l s tat tat ed i ed i nf nf or or mat mat io io n c n c or or res...
- Page 3 Ass Ass emb emb ly ly Pro Pro ced cedur ur e PC4000 e PC4000 Z23038 Z23038 Al Al l s l s tat tat ed i ed i nf nf or or mat mat io io n c n c or or res...
- Page 4 Ass Ass emb emb ly ly Pro Proced ced ur ur e PC4000 e PC4000 PAGE PAGE GENERAL CONTENT GENERAL CONTENT Overviews Overviews Superstructure Superstructure Engine House Engine House 2 2 . . General General Delivery of of the Delivery...
- Page 5 Assemb ly Pro cedur e PC4000 Z22586 PC4000Asrev05 Edition 08/2005...
- Page 6 Ass emb ly Proced ur e PC4000 1.1 Overvi ew Superstructur e (Z22586) Operator's cab with Falling Object Protective Structure (FOPS) Battery main switches Air cleaner for engine Cab support, contains the electric control system Swing circle Fuel tank Hydraulically operated access ladder...
- Page 7 Ass emb ly Pro cedur e PC4000 Z21446 PC4000Asrev05 Edition 08/2005...
- Page 8 Ass emb ly Proced ur e PC4000 1.2 Overview Engi ne House (Z21446) Exhaust mufflers Engine air cleaner Expansion tank for radiator Central control and filter carrier Power take off (PTO) Main hydraulic pumps Auxiliary piggipack hydraulic pumps Hydraulic pump for radiator fan drive...
- Page 9 Ass emb ly Pro cedur e PC4000 PC4000Asrev05 Edition 08/2005...
- Page 10 Ass emb ly Proced ur e PC4000 General Deliv ery of the Excavator The excavator is being delivered disassembled into its main components. For the correct dimensions and weights please refer to the packing list of your machine. For assembling the excavator follow the instructions in this manual.
- Page 11 Ass emb ly Pro cedur e PC4000 PC4000Asrev05 Edition 08/2005...
- Page 12 Ass emb ly Proced ur e PC4000 ã Before assembling/disassembling, lifting or t ransporting thi s • excavator c ont act your l ocal Servi ce Center for all the necessary instr uctions for safe and economic assembling/ disassembling , lifting and transportation procedures of your excavator.
- Page 13 Ass emb ly Pro cedur e PC4000 PC4000Asrev05 Edition 08/2005...
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Page 14: Time Schedule
Ass emb ly Proced ur e PC4000 ã Wear safety clothing, goggles, respirator and other safety • devices, whenever worki ng conditi ons make this necessary. Provide hoists of suffici ent capacity to l ift heavy unit s. Refer to •... - Page 15 Ass emb ly Pro cedur e PC4000 PC4000Asrev05 Edition 08/2005...
- Page 16 Ass emb ly Proced ur e PC4000 Assembl y Site Requi rements Well leveled (not slanting) and compacted ground • approx. 150 x 150 ft/ 50 x 50 m A container to store the tools, to keep the paper work and for sheltering •...
- Page 17 Ass emb ly Pro cedur e PC4000 Yazaki Connector Set Qty. Designation Part No. Connector 3-pole 891 040 40 Connector 3-pole 891 032 40 Connector 2-pole 891 039 40 Connector 2-pole 891 031 40 Connector 1-pole 891 038 40 Connector 1-pole...
- Page 18 Ass emb ly Proced ur e PC4000 Qty. Specificati on Desig nation 5, 6, 8, 10, 12, 14 mm Screw driver sockets for 1/2” drive 14, 17, 19 mm Screw driver sockets for 3/4” drive 2 up to 19 mm...
- Page 19 Ass emb ly Proced ur e PC4000 PC4000Asrev05 Edition 08/2005...
- Page 20 Ass emb ly Proced ur e PC4000 Space and Placing Requir ements On the following pages, the components are indicated in their approx. dimensions. They are unloaded in a way that a min. space of 1 meter (3 ft) is left between the components, and that there is enough space for the trucks and the cranes.
- Page 21 Ass emb ly Pro cedur e PC4000 Z23038 PC4000Asrev05 Edition 08/2005...
- Page 22 Ass emb ly Proced ur e PC4000 Basic Measur ements (Z23038) Transport Dimension s and Weight s (as example) (For exact Dimensions and Weights refer to the packing list of your machine.) Face Shovel Backhoe L.H. and R.H. Crawler s ide f rame L.H.
- Page 23 Ass emb ly Pro cedur e PC4000 Z21859 Z 21859 PC4000Asrev05 Edition 08/2005...
- Page 24 Ass emb ly Proced ur e PC4000 3.1. Ass embl y of Undercarri age (Z21859) Align side frame horizontally in both directions very exactly. From outside place water level gauge onto steel structure of side frame. Pull back all 8 pins (05) out of the outer borings (2+3) of the center section.
- Page 25 Ass emb ly Pro cedur e PC4000 Z23036 PC4000Asrev05 Edition 08/2005...
- Page 26 Ass emb ly Pro cedur e PC4000 3.1.1. Mounting of travel gear breather filters (Z21860) Locate the breather filters of both travel gears in the centre part of • the undercarriage. Route the hoses as shown in the illustration. •...
- Page 27 Ass emb ly Proced ur e PC4000 Z23037 PC4000Asrev05 Edition 08/2005...
- Page 28 Ass emb ly Proced ur e PC4000 3.1.2 Track tensioning system (Z23037) Working position: Closed Ex works: closed Working position: Open Ex works: closed Marking below the washer shows the valve position “O” open “C” closed The valve posit ion (open or cl osed) is not depend on th e lever •...
- Page 29 Ass emb ly Pro cedur e PC4000 Z21863 Z 21863 PC4000Asrev05 Edition 08/2005...
- Page 30 Ass emb ly Proced ur e PC4000 3.2. Assembl y of Superstru ctur e ont o the Undercarriage (Z23863) Attach the superstructure to the cranes, lift up the superstructure and very carefully clean the contact surfaces of the slew ring and the carbody from the paste with a appropriate solvent.
- Page 31 Ass emb ly Pro cedur e PC4000 Z 21863 PC4000Asrev05 Edition 08/2005...
- Page 32 Ass emb ly Proced ur e PC4000 Ass embl y of engin e hou se (Z21863) Attach the unit to the crane (use only the attached lifting points (A). Lower the unit as required so that two bolts with washers (02 + 03) for guiding can be inserted.
- Page 33 Ass emb ly Pro cedur e PC4000 Z21864 Z 21864 PC4000Asrev05 Edition 08/2005...
- Page 34 Ass emb ly Proced ur e PC4000 Mount ing of Boom (Z21864) For the moun tin g of t he pin seals please refer to page 78. • Lift the boom with the cylinders attached.(You can alleviate your job, if you lift the front part of the boom higher than the back part.)
- Page 35 Ass emb ly Pro cedur e PC4000 Z23039 Z 21865a PC4000Asrev05 Edition 08/2005...
- Page 36 Ass emb ly Proced ur e PC4000 3.5. Mount ing of Hydraul ic Oil Tank (Z23039) Lift the Hydraulic Oil Tank. Lifting eyes are delivered with the machine. Align the Hydraulic Oil Tank with the superstructure. Lower the Hydraulic Oil Tank fully down and install all bolts.
- Page 37 Ass emb ly Pro cedur e PC4000 Z21866 Z 21866 PC4000Asrev05 Edition 08/2005...
- Page 38 Ass emb ly Proced ur e PC4000 3.6. Mounti ng of Hydraulic Oil Cooler (Z21866) Lift the Hydraulic Oil Cooler. Lifting eyes are delivered with the machine. Align the Hydraulic Oil Cooler with the superstructure. (Pay attention to the course of the hydraulic lines!) Lower the Hydraulic Oil Cooler fully down and install all 8 bolts .
- Page 39 Ass emb ly Pro cedur e PC4000 Z21867 Z 21867a PC4000Asrev05 Edition 08/2005...
- Page 40 Ass emb ly Proced ur e PC4000 3.7. Mount ing of Fuel Tank (Z21867) Lift the fuel tank. Lifting eyes are delivered with the machine. Align the fuel tank with the superstructure. Lower the fuel tank fully down and install all bolts. Tighten the bolts with the resp.
- Page 41 Ass emb ly Pro cedur e PC4000 Z21871 Z 21871 PC4000Asrev05 Edition 08/2005...
- Page 42 Ass emb ly Proced ur e PC4000 Mounti ng of hydr aulic access ladder (Z21871) Mount hinged ladder(01); Connect ladder lifting cylinder (03); Assemble ladder bearing (17); Tighten the self locking nuts (06) according to the values listed below. Tightenin g Torque of Self Locki ng Nuts (06): New nut: 440 Nm •...
- Page 43 Ass emb ly Pro cedur e PC4000 Z21868 Z 21868 PC4000Asrev05 Edition 08/2005...
- Page 44 Ass emb ly Proced ur e PC4000 3.9. Mount ing of Cab Base (Z21868) Lift the cab base. Lifting eyes are delivered with the machine. Align the cab base with the superstructure. Lower the cab base fully down and install all bolts. Tighten the bolts with the resp.
- Page 45 Ass emb ly Pro cedur e PC4000 Z21869 Z 21869 PC4000Asrev05 Edition 08/2005...
- Page 46 Ass emb ly Proced ur e PC4000 3.10 Mounti ng of Counterweigh t (Z21869) Lift the counterweight with 2 cranes. (The hooks are delivered with the machine). Align the counterweight with the superstructure. Lower the counterweight fully down and fasten it with the bolts(13) and washers (14).
- Page 47 Ass emb ly Pro cedur e PC4000 Z23033 PC4000Asrev05 Edition 08/2005...
- Page 48 Ass emb ly Proced ur e PC4000 3.11 Mounting of Handrail s, Steps and Gratings (Z23033) During this stage of assembly the handrails, steps and gratings can be mounted to the superstructure, cab base and machinery house. This provides more safety during further assembly.
- Page 49 Ass emb ly Proced ur e PC4000 Z22937 PC4000Asrev05 Edition 08/2005...
- Page 50 Ass emb ly Proced ur e PC4000 3.12 Mount ing of Cable transfer to the Operator s Cab (Z22937) The special Cable Transfer Elements for sealing the cab are stored in the cab refrigerator. Install it as shown in the pictures on the previous pages.
- Page 51 Ass emb ly Pro cedur e PC4000 Z22938 PC4000Asrev05 Edition 08/2005...
- Page 52 Ass emb ly Pro cedur e PC4000 Before lowering the cab onto t he cab base mount t he air h ose • to cab bottom. Refer to Illu st. 22940 pos . (8) page 54. PC4000Asrev05 Edition 08/2005...
- Page 53 Ass emb ly Pro cedur e PC4000 Z22939 PC4000Asrev05 Edition 08/2005...
- Page 54 Ass emb ly Proced ur e PC4000 3.13 Mount ing of Cab wi th Support Frame (Z22938; Z22939) Apply sealing compound “ Epple 28” onto the whole contact surfaces (A) of the cab base. The sealing compound is delivered with the machine in a 1 liter can.
- Page 55 Ass emb ly Proced ur e PC4000 Z22940 PC4000Asrev05 Edition 08/2005...
- Page 56 Ass emb ly Proced ur e PC4000 3.13.1 Mount ing of the Cab air cleaner (Cab suppo rt to Cab) (Z22940) Legend for i llu str ation Z22940 1. Air cleaner housing located on cab base 2. Filter element 3. Cab base wall 4.
- Page 57 Ass emb ly Pro cedur e PC4000 Z21873 Z 21873 PC4000Asrev05 Edition 08/2005...
- Page 58 Ass emb ly Proced ur e PC4000 3.14 Mounti ng of Buck et Cylinders (Z21873) Hook up bucket cylinders that way that rod side shows approx. 45° up to the bearings at the boom. Align the rod eyes with borings at the boom. Install pin (1).
- Page 59 Ass emb ly Pro cedur e PC4000 Z 21874 PC4000Asrev05 Edition 08/2005...
- Page 60 Ass emb ly Proced ur e PC4000 3.15 Mounti ng of Stick (Bullc lam buck et) (Z21874) Lift the stick to the bearing position stick to the boom. Lower the stick until stick and boom borings are aligned. Install pin (1), stirrups (2), plate (3), washer (4) and bolt (5).
- Page 61 Ass emb ly Proced ur e PC4000 Z23034 PC4000Asrev05 Edition 08/2005...
- Page 62 Ass emb ly Proced ur e PC4000 3.15.1 Mounting of Stic k (Backhoe attachment ) (Z23034) Legend A Location of Pins with a fine thread end Cap for mounting Final cap Nut for mounting the final cap Nut for mounting whirl...
- Page 63 Ass emb ly Proced ur e PC4000 Z21585 PC4000Asrev05 Edition 08/2005...
- Page 64 Ass Ass emb emb ly ly Pro Proced ced ur ur e PC4000 e PC4000 3. 3.16 Fillin Fillin g g up up hydr hydr aulic aulic oil oil tank tank (Z (Z21 2158 585) 5) Conne Connect all lines...
- Page 65 Ass Ass emb emb ly ly Pro Proced ced ur ur e PC4000 e PC4000 Z22513 Z22513 Z21693 Z21693 PC4000Asrev05 PC4000Asrev05 Edition 08/2005 Edition 08/2005...
- Page 66 Ass Ass emb emb ly ly Pro Proced ced ur ur e PC4000 e PC4000 3. 3.17 Bleed Bleed air air fro fro m m all all hydr hydr aulic aulic pump pump s s and check t check t he Oil L...
- Page 67 Ass emb ly Proced ur e PC4000 PC4000Asrev05 Edition 08/2005...
- Page 68 Ass emb ly Proced ur e PC4000 3.18 Fillin g up fuel tank If so equipped do it via the service arm below the engine house, otherwise fill up direct through the refilling plug on top of the fuel tank.
- Page 69 Ass emb ly Proced ur e PC4000 PC4000Asrev05 Edition 08/2005...
- Page 70 Ass emb ly Proced ur e PC4000 3.19 Pre-checks for ini tial Start-up ã The local workin g safety rul es must be strict ly observed. • Only service personnel necessary fo r fi rst start up testing are •...
- Page 71 Ass emb ly Proced ur e PC4000 PC4000Asrev05 Edition 08/2005...
- Page 72 Ass emb ly Proced ur e PC4000 (13) Connect main battery switch and activate electrical system by using the key switch S1. (14) Check messages from display. (15) Check function of electrical system. (16) Activate swing parking brake by using switch S29 on dash board.
- Page 73 Ass emb ly Pro cedur e PC4000 Z21875 Z 21875 PC4000Asrev05 Edition 08/2005...
- Page 74 Ass emb ly Proced ur e PC4000 3.20 Mounti ng of sti ck cyli nders to the sti ck (Z21875) Hook up stick cylinders to chain pull and remove transport fastening. Lower stick cylinder by means of chain pull. Start the engine and extend cylinder rod. Align with bearing at stick.
- Page 75 Ass emb ly Pro cedur e PC4000 Z21876 Z 21876 PC4000Asrev05 Edition 08/2005...
- Page 76 Ass emb ly Proced ur e PC4000 3.21 Assembl y of Bull clam Buck et to the Stick (Z21876) Deliv ery in tw o part (clam - rear wall) Place the rear wall as shown on the ground. Prepare the pin seals according to page 78.
- Page 77 Ass emb ly Pro cedur e PC4000 Z21877 Z 21877 PC4000Asrev05 Edition 08/2005...
- Page 78 Ass emb ly Proced ur e PC4000 Extend clam cylinders to align them with borings in the clam. Install pins (1) and lock them with catch (2+3). Connect all grease lines to the bucket and ensure that all grease points are greased before machine is put into operation.
- Page 79 Ass emb ly Pro cedur e PC4000 Z22042 Z 22042 PC4000Asrev05 Edition 08/2005...
- Page 80 Ass emb ly Proced ur e PC4000 3.22 Mounting of the Pin Seals (Z22042) The illustration shows the mounting places of the outer bushing seals (A) and the inner bushing seals (B) of the front shovel attachment.. Mounting pro cedure inner pin seals (B):...
- Page 81 Ass emb ly Proced ur e PC4000 Z23035 PC4000Asrev05 Edition 08/2005...
- Page 82 Ass emb ly Proced ur e PC4000 3.22.1 Mount ing of the Pin Seals (Backhoe) (Z23035) Legend il lust r. Z 23035: Upper ring half Lower ring half Seal ring PC4000Asrev05 Edition 08/2005...
- Page 83 Ass emb ly Pro cedur e PC4000 Z21879 Z 21879 PC4000Asrev05 Edition 08/2005...
- Page 84 Ass emb ly Proced ur e PC4000 3.23 Connectio n of the cable harnesses to the termi nal rails in the swi tch bo x “ X2” (Z21879) All harnesses are marked with numbers and letters. You find also these numbers and letters in the X2 –...
- Page 85 Ass emb ly Proced ur e PC4000 Z23039 PC4000Asrev05 Edition 08/2005...
- Page 86 Ass emb ly Proced ur e PC4000 Harnesses Terminal strip Harnesses Terminal strip („going to“) („going to“) Battery box 1 29 Pressure hydraulic oil cooler Engine oil tank 30 Level sensor hydraulic tank Engine 31 Control plate 3 Engine housing...
- Page 87 Ass Ass emb emb ly ly Pro Pro ced cedur ur e PC4000 e PC4000 Z21880 Z21880 Z 21880 Z 21880 PC4000Asrev05 PC4000Asrev05 Edition 08/2005 Edition 08/2005...
- Page 88 Ass Ass emb emb ly ly Pro Proced ced ur ur e PC4000 e PC4000 3. 3.24 Puttin Puttin g g the the Ce Centr ntr al al Lubr Lubr icatio icatio n n System System int int o o operation...
- Page 89 Ass Ass emb emb ly ly Pro Pro ced cedur ur e PC4000 e PC4000 In order to In order to kee keep the excava p the excavator tor in in first-class opera first-class operating c ting c ondition ondition use...
- Page 90 Ass emb ly Proced ur e PC8000 3.25 Metri c standard thr ead Wrench size (mm) Tightenin g tor que MA (Nm) Bolt size (mm) 10.9 12.9 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 1030 M 27...
- Page 91 Ass embly Pro cedur e PC4000 Metric fine thread Wrench size (mm) Tightenin g tor que MA (Nm) Bolt size (mm) 10.9 12.9 M 8x1.00 M 10x1.00 M 12x1.25 M 14x1.50 M 16x1.50 M 18x2.00 M 20x2.00 M 22x2.00 M 24x2.00...
- Page 92 Ass emb ly Pro cedur e PC4000 PC4000Asrev05 Edition 08/2005...
- Page 93 Ass emb ly Pro cedur e PC4000 PC4000Asrev05 Edition 08/2005...
- Page 94 Ass emb ly Pro cedur e PC4000 PC4000Asrev05 Edition 08/2005...